Ingot mold



T. E. DODDS July 25', 1933.

INGOT MOLD Filed May 23, 1931 5 Sheets-Sheet 1 c n n n a fr \\\s .l.lllllll|v FI lllll I.IL

-llllllli` INVENTOR T. E. DODDS July 25, 1933.

INGOT MOLD 5 sheets-sheet 2 Fied May 25V, 1931 INVENTOR 5 u 5 m. .Il W

July 25, 1933. T. E. 'DoDDs 1,919,622

INGOT MOLD Filed May 23, 1931 l :5 Sheets-Sheet 3 INVENTOR WITNESIES ma. @Ma/ www ff WQM July 25, 1933. T. E. DoDDs 1,919,622

INGOT MOLD Filed May 23, 1931 5 Sheets-Sheet 4 WITNESSES INVENTOR I 144% 3.,@ QM. Y l 1%. L i

July25,1933. 1E. DODDS 1,919,622

INGOT MOLD Filed May 25, 1951 5 Sheets-Sheet 5 WITNESSES INVENTOR Patented July 25, 1933 UNITED STAT-Es .PATENT Amfr-'lola'.

x THOMAS E. DODDS, oF MASSENA, NEW YORK, AssIGNoR, To ALUMINUM COMPANY F INGoTsiaoLn Application l'ed May 23, 1.931. Serial No; 539,461.

This invention relates to casting apparatus, and particularly to apparatus for casting ingots for working.

In the casting of some metals, for example aluminum and its alloys, it is desirable that agitation and splashing ofthe metal gots. have an irregular face.

absorbed from the metal.

be avoided as much as possible, particularly `to avoid theentrainment and solidification in the ingot of oXide films and gas. To this end the so-called tiltingmolds have been used widely for making ingots of these metals.

Tilting molds have been satisfactory with relatively small ingots, but they are not well adaptedto the production of very large in- Uots. b More recently there have been proposed molds comprising a vertically movable chill having an opening at one side through which the metal is poured and which is closed by means of a moving wall which progressively moves over the opening as the mold is lowered. An example of this type of apparatus is that shown and described in= U. S. Patent No. 1,7343 86 to Julius Zublin. Such molds are capable of producing useful results, but practical experience with vthem has shown that it is difficult to maintain a metal-tight seal between themold and the closure. This is due to expansion of the chill by the heat metal leaks through the joint, and the in- Subsequent Working of such ingotsjgives products of inferior quality.

This invention relates to casting apparatus of the type just referred to, in which a side opening mold 'is closed progressively during pouring, and its major objects are to provide such apparatus which overcomes the disadvantages of prior apparatus of this type, is of relatively simple construction,

readily used, is adapted to the production of very large ingots, and is particularly adapted for the production of large w`orking ingots of the light metals and their alloys.

The invention may be described'in connection with the accompanying drawings, in which Fig. l is a side elevation of its preferred embodiment, showing it in associa- Vftion with a `melting furnace; Fig. 1f is an In consequence,

end elevation of the mold shown inFig. 1;

Fig. 2 a view Isimilar to Fig. l, on an enlarged scale, showing the mold in its lowered position; Fig. 3 a side elevation on a still larger scale of the closure mechanism shown in Figs. l and 2; Fig. 3a is a fragmentary sectional view of the closure mechanism shown in Fig.

3; Fig. 4 a plan view of the apparatus showr in Figs. l and 2; Fig. 5 a fragmentary front elevation of the closure belt; Fig. 6 a sectional view of the belt taken on the line VI-VI, Fig. 5; Fig. 7'l a fragmentary rear elevation of the upper portion of the closure mechanism shown in Figs. l to 3; Fig. 8 is a fragmentary sectional view of the upper portion of the closure mechanism shown in Fig. s

3; and Fig-9 is a fragmentary exterior view taken in the direction of the larrows IX-IX Fig. 7, parts being broken away to more clearly show the mode of construction. i

The apparatus to which this invention relates comprises a mold member, such as an ingot'chill havingan opening on one side, I

extending the length thereof, which maybeclosed by a flexible closure vmember adapted to move over and progressively close the mold opening. This may take various forms, such as a. sheet steel belt, but preferably it com- ,prises a plurality of closing elements interconnected to form a belt and adapted when in contact with the sides of the opening to form a closure therefor.

reference to the face of the mold opening.

`Most suitably the. belt is supported byl a frame movable toward and lfrom the mold on a base which remains in Xed position relative to the mold as the mold israised and lowered. Additional adjustmenty is also provided by pivotally mounting the upper belt-supporting portion of the frame. v

Thebelt is mounted on rollers in a belt-supporting framework. Y

i justment of the position of the belt face with Thepouring spout through which metal is introduced into the mold is preferably carried by the belt frame, and most suitably the mold is raised and lowered by means of a particular drive presently to be described.

Yin)

Having reference now to the embodiment shown in the drawin s, a mold is constructed from side plates 1 and 2, an end plate l3, and a bottom plate 4 connected to provide a chill of rectangular section having an opening extending along one side thereof through which molten metal is introduced to the ingot by means of a pouring trough 5. In order to facilitate the use of the mold, side plate 1 is connected to base 4 by a hinge pin 1a, and side plate 2 is held in fixed relation to end plate 3 and base 4 by cap screws, not shown. Bolts 6 extending through both side plates and the end plate, and wedges 7 driven in slots in bolts 6 hold side platel in position during pouring, and provide for rapid lowering of this side for removal of the ingots. n

The mold is preferably mounted on pedestal 8 carried by a vertically movable supporting shaft, which in the embodiment shown takes the form of a vertical screw 9 actuated by a nut, not shown, mounted in a gear housing 9a. This nut is driven regulably in any suitable manner, for example by means of a worm gear driven by a motorthrough a multiple speed gear reducer. Such drives being well understood in the art require no further` illustration or description.

As the mold is lowered from the position shown in Fig. 1 to that of Fig. 2 screw 9 moves downwardly into a housing 10 disposed below gear housing 9a. Housing 10' protects the shaft from molten metal splashed during pouring, and from water where it is used for cooling of the mold. A collapsible housing is also provided about the shaft above gear case 9a to protect the shaft exposed there above. This preferably takes the form of interconnected telescoping rings 11 which adapt themselves to the various vertical positions assumed by screw 9.

In order to insure positive alignment of the mold as it is raised and lowered the closed end of the mold moves against a suitable backing up framework, for example H columns 12 carrying rails 13 along which'run rollers 14 lmounted on the corners of the mold.

The closing belt comprises a plurality of bars 15 connected to form an endless belt. Most suitably the bars are provided with .end lugs connected by links 16 of a roller chain having overhung rollers 17, Fig. 5, adapted to engage and run on rotatable collars 18 and 19 mounted 'in a belt-supporting frame r20. In order to permit flexing ofthe articulated joint belt thus formed, bars .15v are `preferably of the trapezoidal section shown in Fig.

. '6. As shown inFigs. 1 to 3, the belt is mounted with the bases of the bars adjacent the open side of the mold.

Actuation` of the belt to move it progressively over the open face of the mold in reythe mold as itis lowered during pouring.

In accordance with the invention leakage Vof metal between the belt and the open face of the mold is prevented by adjusting the face of the closure belt to the open face of the mold tovcompensate for changes due to eX- pansion'of the mold during pouring of an ingot. In this manner the faces of the bars are maintained continuously in metal-sealing contact with the sides of the mold. This is accomplished by mounting belt-supporting frame 20 to be adjustable with respect to the open face of the mold.

Most suitably the frame is movable on a supporting basemounted in fixed position, means being provided for moving the frame toward and from the open face of the mold according to need. As shown in Fig. 3, it is preferred to useva base 21 whose upper surface is provided with rows of supporting rollers 22 mounted to present a rolling surface which slopesdownwardly toward the mold. The frame moves on rollers 22 and is guided in its movement by means of guide rollers 23 which move in grooves formed in base 21.

Movement of the frame with its belt is effected by means of a rack 24 connected to the base, and a pinion 25 suitably mounted in the' frame, as shown, to best advantage in Fig'. 3a. Pinion 25 is 'actuated by a pinion 26 connected to a shaft-27 to which there is keyed a sprocket wheel 28 whose teeth are engaged by the links of a sprocket chain 29 which passes over another sprocket wheel 30rotatably mounted on shaft 30Z1 near the top of the frame. As shown by Fig. 7, shaft 30a also carries another sprocket wheel 31 connected by av sprocket chain 32 engaging the teeth of a sprocket Wheel 33 rotated by means of a hand wheel 34. This mode of supporting the belt provides for adjustment of it to effect proper contact of bars and mold when pouring 'is started, and to maintain such contact in the portions containing solid metal.

A counterweight 35 connected in sprocket chain 29 maintains a dog 36in engagement with a ratchet 37, associated with sprocket 31. Through rotation of hand Wheel 34 the i frame may be moved as desired, and it is fixed by ratchet 37 at any particular position. The counterweight moves in a guide 38 to avoid the possibility of over travel of chain 29. The side of frame20 adjacent the mold is ma\. chined along raised surfaces to provide a smooth track for rollers 17 of the belt;

Adjustment to compensate for expansion is provided by pivotally mounting the top section 39 of the frame, carrying rollers 18, on a shaft 40. Adjustment of this-section is had by means of eccentric links 41, Figs. 3 and 7, connected at one end to shaft 18EL carrying belt rollers 18, and at the other end to eccentrics 42 mounted on shaft 43 in arms 44 carried by frame 20. Rotation of the hand Wheel 45 which is keyed to shaft 43 imparts lateral motion to the shaft 18a carrying rollers 1 8, the extremities of the shaft 18a being supported in elongated openings in the arms 44 of the frame 20, and vthus the top section of the belt is shifted relative to the face o f the mold.

-The eccentrics may be locked in any desired position by means of a lock nut 46 movable on a threaded portion of shaft 43. Depending upon the position of top section 39 relative to frame 20 the distance between the centers of belt rollers 18 and 19 will vary. In order to compensate for this shaft 19a carrying roller 19 is mounted in slots 47 formed in the frame, and it is acted upon at its ends by springs 48, Fig. 3, the tension being adjustable by thumb screws 49. In this manner the closing belt is held under a constant tension. As shown in Fig. l, the mold is preferably i associated with a melting furnace, such as an electrically heated ladle 50 mounted to pivot about an axis 51. Metal passes from the ladle into trough 5 and tlfence to the mold.

i begun the lowering mechanism is started to The appara-tus preferably is provided` with' means for adjustably carrying pouring trough 5. Mounted upon shaft 43 is a troughsupporting bracket 51Il having an arm 52 connected to a clevis 53 mounted on a shaft-54 rotatably carried in arms 44. Shaft 54 is rotated bymeans of a lever 55, vand a clamp nut 56 permits locking the bracket in any desired position. The bracket is preferably provided with tapped holes 57 for holding pouring trough 5 in the bracket. This provides means for shifting the angle of the pouring trough to maintain its slope constant during the filling of the mold.

i In the use of this apparatus the trough is set so that it extends into the mold `with its open end practically at the bottom thereof when the mold is in its highest position, land frame 20 vis moved inthe manner described hereinabove to cause appropriate contact between the bars l5 and the bottom of the mold; This is shown in Fig. 1. When pouring has lower the mold as the level of metal rises within, the speed of lowering being `.such that the levelL of the metal remains constant with respect toA the trough. In this manner surging. of the metal is eliminated, and quiet transfer of metal from the ladle to the mold is effected. As soon as the mold begins to move 4downwardly dogs 15l cause the belt to move, and successive bars are brought progressively into contact with the mold face, therebyv forming a continuous closure for the open side. As pouring progresses the front, or open, edge of the mold varies beto represent its best embodiment.

cause of the expansion. of the more highly heated lower portion. This causes the portion of the mold already filled to press against the bars, and it impairs the joint betweenthe bars and the mold in the upper portion where there is molten metal. In `prior apparatus of this type such expansion therefore caused leakage of metal between the faces of the bars and that of the open end of the mold. Such leakage is eliminated in this apparatus. Metal-tight contact is maintained through adjustment of the upper section of the belt, as'described hereinabove. Further adjustment is had also, if necessary, by shifting the belt in its entirety by moving frame 2O on its base.

In the preferred embodiment of the invention the mold is lowered through an adjustable speed direct current motor 58 whose speed can be controlled within wide limits. Screw 9 is` driven"by this motor through a gearl reduction unit 59, of any suitable type, and an alternating current motor 60 connected by a coupling 61 to the nut-actuating The ingot is then removed for rolling. Eye bolts 61a are provided in the side and end plates to facilitate handling the mold and its members, and the mold is quickly andaccurately positioned onpedestal 8 by means of lugs 63, Fig. 2, integral therewith which receive studs 64 on base plate'4. This drive assembly permits accurate control of the mold lowering speed, togethenwith rapid return `to its upper position. For safety of operation the mold is provided with limit switches inserted in the circuits of motors 58 and 60, whereby the position of the mold is accurately controlled.

According t`o the provisions of the patent statutes, I have-explained the principle and operation of my invention and have illustrated and described-"what I now consider However, I desire to have it understoodthat, within the scope of the append-ed claims, the invention may be practiced otherwise thany as specifically illustrated and described.

`Iclaim:

1, An ingot castinglapp'aratus onisng.

a mold member having a side opening, a flexible closure belt member mounted to contact with the sides of said opening to form a substantially continuous closure therefor,

means for moving one of said members relative to the other member to cause the belt -to move progressively over and close said opening, and means for adjusting Vthe posi- 'tion of said belt laterally and angular-ly to said opening to continuously maintain metalsealing contact between the belt and the sides of the opening as the mold expands unevenly under heat.

2. An ingot casting apparatus comprising a vertically movable mold having a side opening, means for progressively closing said opening as the mold is lowered comprising a flexible belt mounted to contact with the sides of and move progressively over saidJ opening to form a substantially continuous closure therefor as the mold is lowered, means for moving the entire belt laterally toward and from the open side, and means for independently moving the upper portion of the belt toward said opening.

3. An ingot casting apparatus comprising a vertically movable mold having a side opening, a frame disposed infront of said opening and having an upper portion mounted pivotally for movement toward said opening, a closure belt carried by the frame and said pivotally mounted portion comprising bars interconnected at their ends to yform an endless belt, the bars being moved -v progressively form a substantially continuous closure therefor as the mold is lowered, means for moving the frame toward and l from the side opening, and means for moving said pivoted portion toward the opening, said last mentioned means being adapted to maintain continuous metal-sealing contact of the belt with said opening as the mold expands under heat. l

5. An ingotcasting apparatus comprising a vertically movable mold having a side opening, means for progressively closing said 'opening comprising a plurality of bars connected at their ends to form an endless belt, 'lowering of the mold causing the beltto move and bring the bars successively into contact with the sides of said opening to progressively close it, means for moving the belt as a` Whole toward and from the side opening, means for independently moving the upper portion of the belt toward said opening, whereby to maintain metal-sealing contact of the barswith the mold as lit expands under heat, and means or raising and lowering said mold comprising a shaft supporting the mold, gear drive mechanism cooperating with said shaft, an alternating current motor coupled to said gear mechanism for elevating the mold, a-direct current variable speed motor driving said .gear mechanism through said alternating current motor for lowering the mold, and a magnetic clutch disposed between said motors for cutting out the direct current motor when the mold has beenv lowered.

n V6. An ingot casting apparatus comprising a vertically movable mold having a side opening, means for progressively closing said side opening as the mold is lowered comprising a flexible closure belt, a frame having its base sloped toward the open side of the mold, said frame being adapted to support the flexible closure belt, a complementary sloped base member for supporting said frame, a rack attached to said base member, a pinion rotatably mounted in said frame in mesh with said rack, sprocket and chain driving means associated with said frame adapted to rotate said pinion and translate the frame towards and away from the mold side opening, and ratchet means associated with said sprocket and chain driving mea-ns for-locking the vframe in various positions with respect to the base member.

7. VAn ingot casting apparatus comprising a vertically movable mold having a side open-v ing, means for progressively closing said side opening as the mold is lowered comprising a flexible belt mounted to contact with the sides of the openingand move progressively over said opening, a flexible belt-supporting frame having an upper portion pivotally attached thereto, said flexible belt being supported at its upper end upon said pivotallyattached portion of the belt-supporting frame, eccentric links supported upon eccentrics mounted upon a rotatable shaft in said frame and connected to said pivotally attached portion whereby the upper portion of the flexible belt may be independently moved towards and away from the open side of the mold, a. sloping base member rigidlysecured adjacent the opening in the mold adapted to support said flexible belt-supporting frame,-said frame having a complementary base portion in contact with rollers rotatably mountedin said base member, a rack attached to said base member, a pinion rotatably mounted in said frame in mesh with said rack, a sprocket and chain driving means mounted in said frame and associated with said pinion whereby the frame may be translated in its entirety towards and away from said opening in the mold, means for actuating said sprocket and chain driving means, and means incorporated in said sprocket and chain driving means :for fixing the position of the frame relative to the mold.

8. An ingot casting apparatus comprising a vertically movable mold having a side opening, means for progressively closing said side opening as the mold is lowered comprising a flexible belt mounted to contact with the sides of the opening and move progressively over said opening, a ieXible belt-supporting frame mounted for translation towards and away from said opening, said frame having an upper belt-supporting portionpivotally attached thereto, eccentric links supported upon eccentrics secured to a rotatable shaft mounted in said frame, said eccentric links being connected to said pivotally attached portion of the frame for pivoting the upper portion of the belt towards and away from said side opening, and means for translating the belt-supporting frame in its entirety towards and away from said side opening.

9. An ingot casting apparatus comprising a vertically movable mold having a side opening, means for progressively closing said side opening as the mold is lowered comprising a HeXible belt mounted to contact with the sides of the opening and move progressively over said opening, a flexible belt-supporting frame mounted for translation towards and away from said opening, said 'frame having an upper belt-supporting portion pivotally attached thereto, eccentric links supported upon eocentrics secured to a rotatable shaft mounted in said frame, said eccentric links being connected to said pivotally attached portion of the frame for pivoting the upper portion of the belt towards and away from said side opening, locking means associated with said rotatable shaft for securing the same and iixing the position of the upper portion of the belt with respect to the mold side opening, and means for translating the belt-supporting frame in its entirety towards and away from said side opening.

THOMAS E. DODDS. 

